Method of building with cementitious material applied to vegetable fabrics



2 Sheets-Sheet l Aprll 17, 1934. J. H. DE w. WALLER METHOD OF BUILDINGWITH CEMENTITIOUS MATERIAL APPLIED TO VEGETABLE FABRICS Filed March 9,1932 2 Sheets-Sheet 2 April 1934- J. H. DE w. WALLER METHOD OF BUILDINGWITH CEMENTITIOUS MATERIAL APPLIED TO VEGETABLE FABRICS Filed March 9,1932 Patented Apr. 17, 1934 UNITED STATES PATENT @FFECE METHOD OFBUILDING WITH GEMENTI- TIOUS MATERIAL APPLIED TO VEGETABLE FABRICSApplication March 9, 1932, Serial No. 597,838 In Great Britain March 28,1931 4 Claims. (Cl. 72-1) This invention relates to a method of buildingwith cementitiousmaterials reinforced with woven vegetable fabrics.

One of the objects of the invention is to devise means for buildingstructures which will be cheap and economical. Another object of theinvention is to build structures which have great strength but at thesame time are very light. A further object of the invention is to avoidthe use of moulds or shuttering when building such structures. In orderthat the invention may be clearly understood reference will be made tothe accompanying drawings which give some examples of its variousapplications and in which:-

Figure 1 shows a cross-section of a pillar or support.

Figure 2 shows a cross-section of a pipe.

Figure 3 shows a horizontal section of a portion of a double wall.

Figure 4 shows a vertical section through a wall plate.

Figure 5 shows a vertical section of a portion of a double wall.

Figure 6 shows a vertical section through a roof. I

Figure 7 shows a section of a barrel.

Figure 8 shows a vertical section of part of a Pillars or posts may bemade as shown in Figure 1 by forming a tube 1 having the requireddiameter of Hessian 2 or other flexible material with a fairly coarse oropen mesh and suspending this by any suitable means. Fluid material 3such as concrete, cement, plaster, or the like is then poured into thetube which has preferably been wetted beforehand. The initial tensilestress is given to the Hessian by the weight of the fluid material andthe shrinkage. The finer parts of the material 3 such as the sand andcement will ooze out of the small holes until the Hessian is completelyencased in material. Additional cement, plaster, or the like may beadded to the outside if required and any desired finish or colouringeffect may be given to this. Metal reinforcing such as wires, rods orthe like may be placed in or around the Hessian tube before filling withmaterial where extra strength is necessary. The setting of the cementmaintains the initial tensile stress in the flexible material.

Pipes can be made as shown in Figure 2 in which the I-Iessian 2 in theform of a long strip is wound helically as tightly as possible upon acollapsible mandrel or core 4. It is then preferably wetted and coatedwith a slurry or paste of cement, concrete, or the like. After thiscoating is dry a further layer in the form of a paste or mortar of anysuitable material is added. The mandrel 4 is then removed and the insidesurface may be coated if desired with a layer of cement, concrete,plaster, or the like by any suitable means. The shrinkage and theinitial tension produce the permanent tension in the reinforcement ofthe finished pipe.

Walls may be made as illustrated in Figure 3 which shows one of thesupports 5 to which the Hessian is fastened, the other ends of theHessian being stretched and fastened to one or more other supportsaccordingto the length of the wall. The Hessian 2 is secured byincorporation in the concrete pillar or support 5 by being enclosedwithin the wooden shuttering when casting the pillar. The opposite sideof the pillar is provided with a timber insulating and fixing strip 6which is secured to the pillar 5 by means of nails '7 and staples 8 orany other suitable means. The Hessian 2 is preferably wetted and thencovered with a thin paste or slurry of concrete or cement and when dryis covered over with a layer 13 on the outside of concrete or cement toform the outside wall 0. A thin layer 14 of concrete or cement is thencovered over the inner side of the Hessian 2. If it is desired to form adouble wall another length of Hessian 2 is secured to the strip 6 bysuitable nails or the like (the heads of which are left projecting) andthe Hessian is covered over with a rendering of plaster or the like 15which is pressed through the open meshes of the Hessian to form an innercoating 16.

The top of the Hessian 2 of the outside wall 0 is cast into the wallplate 17 as shown in Figure 4 while the Hessian of the inner wall I issecured to a timber rail 18 cast into the top rail. The bottom of theHessian may be secured in a similar manner. The Hessian is stretched astightly as possible over the framing to produce an initial tension whichis considerably increased by the shrinkage produced by the applicationof water or by the wet concrete or cement and is maintained in thematerial by the setting of the concrete, cement, or the like.

If desired the timber insulating and fixing strip 6 may be made withtaper sides and then surrounded upon three sides with the concrete.Instead of making the pillars or supports of concrete these may be madeof timber as shown in Figure 6, the Hessian being nailed thereto andsuitable nails or spikes being driven in to provide an anchorage for thelayers 13 and 15 of concrete, plaster, or the like.

A covering of cement or plaster from one quarter to one half inch thickeither on one or both sides of the Hessian forms a very substantialwall.

When windows or other openings are required it is only necessary torefrain from plastering over this space by placing a wooden frame orboard in the required position. When the plastering is set the frame orboard is removed and the Hessian can be cut out or burnt away thusleaving the required opening.

Roofs can be very simply and easily made according to my invention. Aridge-post 20 or the like as shown in Figure 6 is mounted in the required position and dry Hessian 2 of the desired length and width isthen draped over the ridgepole and brought down and secured over thewalls at 21 and continued if desired as shown in dotted lines to formthe eaves where it is attached to suitable poles or the like to keep itstretched out to the desired curve. If required wire netting or othermetal reinforcement may be placed under the Hessian to prevent itsagging too much. A layer of cement or concrete plaster 23 is thenplaced over the whole of the outside of the Hessian 2 which acts as thereinforcing means and also the supporting means. When this outer layeris sufficiently set a layer of cement or other plaster 24 is placed uponthe underside of the Hessian to enclose completely the Hessian and wirenetting, if such is used. The space between the wall plate and theHessian is preferably filled with concrete 25 to assist in securing theroof to the wall. The poles are then removed and a monolithic roof ofgreat strength and lightness is produced.

In this case the Hessian shrinks as before and the tension is providedby the weight of the fluid material placed upon it.

The gables at each end can be made by plastering a piece of Hessian ofthe required shape placed and shrunk in position either before or afterthe plastering of the roof.

According to another application of the invention I can form barrels asshown in Figure '7 by fastening the dry Hessian to two hoops 30, 31which can be kept apart by suitable members so as to hold the Hessiantaut. If desired further intermediate hoops 32 may be employed atdifferent points to keep the Hessian stretched in a circumferentialdirection. The Hessian 2 is preferably shrunk with Water and thencovered with a paste or slurry of concrete, cement, or the like by meansof a brush to set the material with an initial tensile stress which isobtained by the shrinkage. It is then plastered with a layer 34 of theconcrete, cement, or the like.

According to another application of the invention, as shown in Figure 8floors can be very easily made upon ground which is levelled andprepared for the purpose. The usual footing 40 is provided and holes aremade in the ground at regular intervals by means of a crowbar or thelike and these are filled with concrete up to the level of the footingat) to form supports 41. A layer of sand 42 is then spread over theground level with the supports and the Hessian 2 is laid on top of thisand when stretched is securely fastened to the footing 40 all round thefloor. Concrete 43 of fairly liquid consistency is then spread all overthe Hessian 2 to a thickness of about one inch. If necessary a thincoating can be given first of all with a brush. The finest particles ofthis concrete will pass through the mesh of the Hessian and unite withthe sand thus forming a complete casing enclosing the Hessian. Themoisture and cement will shrink the Hessian and together with its weightgive it the initial tensile stress. If desired a thin layer of concretecould be placed upon the ground first and then when dry the Hessian laiddown upon it, secured to the frame, shrunk and covered with concrete. Ora second layer of Hessian 2 could be laid down so as to form a doublereinforcement when extra strength is required.

In all applications of the invention the paste or slurry which isapplied with a brush may be made of quick setting cement and theplastering done with ordinary cement.

Upper floors may be made as shown in Figure 9, the Hessian 2 being fixedto the top of the wall plate 17 and supported upon joists 44. TheHessian 2 is wetted and covered with a layer of concrete or the like theweight of which keeps the initial tension in the Hessian. A furthercoating of concrete 45 or the like may be added and levelled off.

Walls and floors may very conveniently be built of units as shown inFigures 10 and 11 which comprise hollow tubular members 50 of anysuitable length say nine or ten feet long having a rectangular sectionof say twelve to eighteen inches by six inches. Four longitudinalmembers of timber are arranged in parallel at the four corners of arectangle which is small compared with their length and are maintainedin such parallel alignment by means of bracing or supports situated atthe ends of said longitudinal members and at intermediate points ifnecessary. Such bracing or supports are secured in such a manner thatthey can be easily and quickly dismantled. Over the framework a piece ofHessian or other suitable material composed of vegetable fibres iswrapped and securely fastened so as to keep the whole material taut andin a state of tension.

This hollow rectangular tube of material is preferably shrunk with waterand is then covered over with a slurry or paste of concrete, cement,plaster, or other suitable material and when this is set a further layerof concrete, cement, plaster, or the like is spread all over theexterior of the tube. When this is set the bracing or supports of thelongitudinal members are dismantled and the longitudinal members removedleaving a tubular member of rectangular cross-section having areinforcement of Hessian or other material composed of vegetable fibres.The bracing or supports may be of any suitable form.

The Hessian is of fairly open mesh so that the slurry or paste willpenetrate through the material and form a protecting coating on theinside of the tube. If however a thicker coating is required a thinpaste or slurry can be poured through the tube so as to run along theinside walls and this can be done one or more times to of metal and maybe permanently left in the member 50 or may be removed as required.

Such tubular members may be made of any desired length say about 10 feetor so and can be laid side by side upon the supporting walls to form thefloors and ceilings of the upper stories of buildings. The joints can begrouted with cement mortar and the whole covered with a layer ofconcrete either reinforced or not as desired to form the floor while theunderside may be plastered to form the ceiling in the usual manner. Whendesired a space may be left between any two tubular members (say fourinches or so) and a reinforcing bar placed in this space which whenfilled with concrete will form a joist between the two members. Anynumber of joists may thus be formed. The floors may be covered with woodor any other suitable covering.

In order to build a wall such tubular members may be made of any lengthand may be laid horizontally or vertically and bonded together by cementmortar or the like and the outside and inside being then covered by athin layer of concrete, cement, plaster, or the like.

Walls constructed in this manner are very suitable for domesticbuildings since they are provided with hollow spaces and therefore willbe warm in winter and cool in summer and at the same time are light inconstruction and cheap to manufacture.

Stairs, beams and innumerable other structures can be made according tomy invention.

The initial tensile stress in the flexible material adds very materiallyto the strength of the reinforcement and further prevents cracking ofthe concrete at a later period.

It is to be understood that various other uses may be found for theinvention and means, methods, and materials other than those describedmay be employed according to circumstances without departing from thescope of the invention.

I claim:

1. A method of building structures with cementitious material whichsubsequently sets hard consisting in first stretching a supporting andreinforcing flexible material composed solely of vegetable materialbetween fixed supports so as to impart an initial tension thereto,thereafter wetting the fabric to cause it to shrink and thereby greatlyincrease the tension therein, applying cementitious material to thefabric when still wet so that particles of the cementitious materialpenetrate into the pores and interstices of the vegetable fabric andthereby maintain the increased tension in the fabric when thecementitious material sets hard.

2. A method of building structures with cementitious material whichconsists in first stretching a woven vegetable fabric between fixedsupports, said fabric acting as the sole reinforcing means for thestructure, thereafter applying thereto a coating of very wetcementitious material so that the moisture therein causes the fabric toshrink and thereby be placed under additional tension, fine particles ofthe cementitious material being carried into the pores and intersticesof the fabric, and thereafter applying a further coating of cementitiousmaterial.

3. A method of building structures with cementitious material whichconsists in first stretching a woven vegetable fabric between fixedsupports, said fabric acting as the sole reinforcing means for thestructure, thereafter applying thereto a coating of very wetcementitious material so that the moisture therein causes the fabric toshrink and thereby be placed underadditional tension, fine particles ofthe cementitious material being carried into the pores and intersticesof the fabric, and maintaining the increased tension in the fabric whenthe cementitious material sets.

4. A method of building structures with cementitious material whichconsists in first stretching a woven vegetable fabric between fixedsupports, thereafter applying thereto, by means of a brush, a thincoating of very wet cementitious material so that the moisture thereincauses the fabric to shrink and thereby be placed under additional 1tension, fine particles of the cementitious material being carried intothe pores and interstices of the fabric, and maintaining the increasedtension in the fabric when the cementitious material sets,

and finally applying at least one further coating of cementitiousmaterial thereto in the form of a plaster.

JAMES HARDRESS DE WARRENNE WALLER.

